EZ ELECTRIC POWER STEERING

Installation manualJaguar XK120

10­02­2014

EZ­XK120­1: Input tubeEZ­XK120­2: Output tubeEZ­XK120­3: Output shaftEZ­XK120­4: SpeedsensorEZ­XK120­5: EZ wire harnessEZ­XK120­6: EZ ECUEZ­XK120­7: Contactpin holderEZ­XK120­8: Input shaftEZ­XK120­9: Output tube Flange.EZ­XK120­10: Clamp output tube.

Contents

4. Remove Horn button and pull it asmuch as possible from the steeringshaft. If needed feed the wire below atthe steering box to give moreclearance. Cut the wire at the switch,be sure to leave enough lenght toreconnect the wires from the EZ unitafterwards. Pull the remaining wiresthrough the steering box out!

1. Check tyre pressure and take the car for a test drive and check the originalsteering system for faults. When all OK continue with the conversion.

2. Locate a ignition switched feed wire, to control the EZ ecu. See point (30).Label this wire.

3. Disconnect batterie earth. Allign the front wheels, mark this postion on thesteeringbox.

6. Remove cover underneath dashbordand remove clamp from which holdthe steering pipe.

5. Remove clip and remove steeringwheel.

7. Cut the pipe in the enginecompartment, with a pipe cutter.Remove the upper part afterwards.Also fit a cloth around the steeringshaft into the remaining steering pipe.To prevent contamination. CAUTION:at a RHD drive car its needed toremove the rear carburetor. Seepicture 7a for more details.

8. Cut the steering shaft, see picture 8afor more details.

7a. Measured from the firewall the pipeneeds to be cut at 400mm(15,75inch).

8a. Measured from the firewall the shaftneeds to be cut at 220mm (8,75inch).

10. Use a hammer with a round bar anduse it to tap the small pipe out of thesteering box. Once it about 21 cmthrough its enough.

11. Tighten the clamp and cut off 20 cmfrom the pipe which sticks out thesteering box.

9. Loosen the clamp at the steering box.

12. Fit the original gaiter around theremaining steering pipe.

13. To give the EPS unit enoughclearance, it's necessary to removesome material. See photo's for howit's done. The 2 excisting openingsneed to be merged to one opening.NOTE; this manual is about a LHDvehicle. In case from a RHD vehicle,normally a mirror image can be used,Use the EZ unit to get the exactlocation to cut.

14. The complete set is delivered assembled, and needs to de disassembled tobe able to fit it. See photo below. The EPS kit is fitted piece by piece into thecar!

15. Remove contact pin holder (041­7)

16. Remove output tube (041­1) fromthe EZ unit. This is screwed on.

17. Remove inputshaft (041­8) from theEZ unit. This shaft is fixed with anallen bolt. Remove this first!

18. Remove Output shaft (041­3) fromthe EZ unit. After removal from theclamp bolt, the shaft can be pulledof the unit!

19. Install the output shaft (041­3) in theoriginal steering shaft. The Clamp(041­10) can be fitted over theoriginal Steering tube. Once this isdone, install de EZ output tube overthe Original steering tube. (Do notforget the clamp before installingthis).

20. Fit output flange (041­9) into the car.The EZ unit can be fitted into thecar afterwards.

21. Fit the output shaft (041­3) to theunit.

25. Install the output flange to the EZunit.

24.Install/screw the input tube on the EZunit.

23. Fit input shaft and lock this with theallen bolt. Use lock­tite when doingthe final installation from this bolt!

22. Install the lock nut on the input sideof the EZ unit.

26. Fit output pipe 041­5 temporarly tothe EPS unit. Check alignment anddepth against the dash together withthe allignment from openings againstthe contact rings on the input side.When all OK, tighten the lock nut andthe clamp from the iinnppuutt pipe (041­1)and fit the holder (041­7).

29. Find a suitable location for the ECUand mount it to the car.

27. Remove output pipe from the unit (0415­2), it can be slided back over theoriginal pipe. Weld the EPS output shaft (041­3) to the original steering shaft!Slide the output pipe back onto it's position again and lock itwith the lock nut. And tighten the clamp.28. Install earlier fitted gaiter around steering pipe and firewall (see point 12).

30. Connect the wiring to the ECU.31. Connect the thick red wire (30+) via the fuseholder directly to the battery +32. Connect the thin red wire to an ignition switched feed wire (see point 2).33. Connect the black wire (31­) to an suitable earth point

34. Make sure the original wiring doesn't short circuit!35. To test the system reconnect the battery earth and turn on the iginition. Afterthis a click should be noticeable. The system is now operational, check this.After turning off the ignition it takes about 3 seconds before the EPS unitswitches off. Again a click should be noticeable. If all OK. Disconnect thebattery earth again.36. Install the steering wheel.37. Install the contact pins into the holder. CAUTION: Do not overtighten them.38. Connect the wiring from the indicators and horn with the contact pins.39. Isolate the wiring in the steering shaft.

40. Shorten the pipe from the indicatorswitch as much as possible (seealso picture 40a)..

41. Reconnect the indicator switch and test it. Mount it in the car afterwards.CAUTION: watch the wiring while fitting it, together with the depth.42. Make sure all the wiring is fitted and strapped OK.43. Fit the cover underneath the dashbord.44. Reconnect the battery earth and take the car for a test drive. Recheck allsystems.

40a. Be sure to leave enough lenghtfrom the wires, to reconnect them.